Process for the preparation of a modified polytetrafluoroethylene and its use

ABSTRACT

If the employment of polymerization auxiliaries in ammonium form is avoided in the preparation of a polytetrafluoroethylene having a content of 0.02 to 1% by weight of units of a perfluoro-(alkyl vinyl) ether by the suspension process, a polymer which does not tend to discoloration on heating is obtained.

This application is a continuation of Ser. No. 08/310,633 filed Sep. 22,1994 abandoned.

The invention relates to a suspension polymerization process for thepreparation of a modified polytetrafluoroethylene (PTFE) which suffersno discoloration when large moldings produced therefrom are processed bythe preform sintering technique. "Modified" PTFE means that thetetrafluoroethylene (TFE) polymer contains low amounts of "modifying"comonomers, but the copolymers like homopolymeric PTFE--cannot beprocessed from the melt.

Molding powders of a polytetrafluoroethylene having a low content of aperfluoro-(alkyl vinyl) ether with an alkyl group of up to 5 carbonatoms are known in two forms, for example from U.S. Pat. No. 3,855,191in the form which is not free-flowing and from U.S. Pat. No. 4,078,134in the free-flowing form. The free-flowing form offers advantages in themetering and charging of processing machines, but the moldings fromgoods which are not free-flowing--as is also the case with non-modifiedPTFE--show significantly better mechanical and electrical properties.

By modification with the perfluoro-(alkyl vinyl) ether, the tendency tocrystallize from the melt is inhibited, which means that the amorphouscontent is increased. The good mechanical properties, such as tearstrength and elongation at break, can thereby already be achieved atsignificantly lower molecular weights than in the case of non-modifiedpolytetrafluoroethylene.

The lower molecular weights of the modified products manifest themselvesin an Ajroldi melt viscosity (U.S. Pat. No. 3,855,191, column 8) ofabout 1 to 100 GPas, while the non-modified polymers have values of morethan 300 GPas, having comparably good mechanical properties.

As a result of this drastic reduction in melt viscosity, the propertiesof the moldings produced from these modified molding powders areimproved. Since the particles of the molding powder fuse more easily,the moldings contain fewer pores and as a result have improveddielectric strength, and furthermore the creep resistance is virtuallydoubled. Above all, however, the weldability of the moldings is improvedconsiderably.

Nevertheless, the moldings often show considerable discoloration duringprocessing by sintering, and above all in the sintering of largermoldings, especially if molding powders which are not free-flowing areemployed. This discoloration is usually not distributed homogeneouslyover the molding, but as a rule brown streaks occur. Since such plasticsare employed only for high-quality goods, this inhomogeneous aspect isextremely undesirable, even if the technical properties are notnoticeably impaired thereby.

Such discolorations have also already been found with non-modified PTFEand have been attributed to contamination by metal ions as a result ofcorrosion of the stainless steel polymerization vessels (U.S. Pat. No.3,629,219, column 3, lines 7 et seq.). As a remedy, the addition ofbuffers for buffering corrosive acids is recommended there.

However, this effect cannot be decisive by itself in the case ofpolymers modified by perfluoro-(alkyl vinyl) ethers, since, even whensuch buffers are employed and in the case of polymerization in enamelvessels, the discolorations mentioned occur during the heat treatment ofthe moldings produced from the polymers thus obtained.

It has now been found that this adverse discoloration does not occur ifthe employment of ammonium compounds is substantially or preferablycompletely avoided during the polymerization. This finding isexceptionally surprising, since ammonium compounds are employed quitegenerally as initiators, activators, dispersing agents and buffersbecause of their good solubility. Thus, U.S. Pat. No. 3,629,219expressly recommends, in column 3, lines 31 to 37, the employment ofammonium buffers, initiators and activators to avoid discoloration ofthe sintered product.

It has furthermore been found that the modified polymers prepared on anindustrial scale in the customary manner employing ammonium compoundscannot be freed adequately and reliably from the adhering ammoniumcompounds even by extensive washing. Indeed, intensive washing of theproducts often leads to an increase in the brown streaks. This effect isprobably attributable to the fact that the residual amount of buffer isremoved before the residual amount of monomers. On oxidation of theseresidual monomers, strong acids are formed, for exampleperfluoropropionic acid from perfluoro-(propyl vinyl) ether, which maycorrode metal surfaces of the components of the processing plant and maythus entrain metal ions. In this case, the discolorations would then beattributable to contamination by metal--as described in U.S. Pat. No.3,629,219.

According to the invention, the suspension polymerization is thereforecarried out in a manner which is known per se, but in which thepolymerization auxiliaries essentially are not employed in the form ofammonium salts. "Essentially" means that at least about 80%, preferablyat least about 90%, of the cations of the chemicals added are notammonium ions. Advantageously, ammonium compounds are avoidedcompletely.

Preferred embodiments of the process according to the invention areillustrated in detail below.

The polymerization is carried out by the known suspension process attemperatures of 60° to 130° C., preferably 60° to 80° C., and undertetrafluoroethylene pressures of about 4 to about 25 bar, preferably 5to 15 bar. The perfluoro-(alkyl vinyl) ether, preferablyperfluoro-(n-propyl vinyl) ether (PPVE), is metered into the process inan amount such that the polymer contains 0.01 to 1% by weight,preferably 0.02 to 0.25% by weight, of ethermonomer units.

Suitable initiators are persulfates, the alkaline earth metal saltsbeing possible in principle. However, the lithium, sodium and potassiumsalts are preferred because of their better solubility.

Preferred buffers are substances which are not strongly alkaline, sincethese can sometimes lead to a slight, although homogeneous,discoloration. The alkali metal mono- and diphosphates, alkali metalformates and trifluoroacetates are suitable. The alkali metal oxalatesand hydrogen oxalates, in particular the sodium and potassium salts,which are not oxidizing under the conditions used, are preferred.

The addition of a buffer is not essential in many cases, but providesthe advantage that corrosion of the components of the plant is reducedand the pH-dependent rate of dissociation of the initiator remainsconstant, which leads to a polymerization time which can be monitoredand to better control of the molecular weight distribution.

Organic auxiliary chemicals, such as citric acid, or organic initiators,such as disuccinic acid peroxide, are not advantageous, since they canlead to discoloration of the product if not removed adequately.

The perfluoro-(alkyl vinyl) ether is preferably added such that theincorporation rate is essentially constant over the polymerization time.However, initial introduction of all the ether also leads to a productwith good properties.

The addition of a dispersing auxiliary can advantageously be dispensedwith in the process according to the invention. The occurrence of lumps,through which the reaction may become uncontrollable, is thus avoided.

The polymerization can also be carried out by the process known fromU.S. Pat. No. 5,153,285, in which a mixture of TFE and inert gas isforced in before the polymerization and the total pressure of themixture forced in is 5 to 50 bar, the concentration of the TFE in thismixture being 30 to 70 mol % and being kept in this range by appropriatetopping-up during the polymerization.

The advantageous properties of the products obtained according to theinvention can be seen from the following examples. The results aresummarized in the form of a table, Examples 1 to 10 showing theconventional procedure and Examples 11 to 19 showing the processaccording to the invention. The examples contain repetitions with thesame test parameters which show that no discoloration is achieved evenwith the known process--in individual cases. Products having an averagePPVE content of 0.04 or 0.09% by weight are prepared (corresponding tocustomary commercial products).

The PPVE incorporation stated in the table is determined by IRspectroscopy by measurement of the absorption A at 994 and 2367 cm⁻¹ ona 100 μm thick film, in accordance with the following equation: ##EQU1##

The standard specific gravity is determined in accordance with ASTM teststandard D-1457-69.

Furthermore the tear strengths and elongations at break have beenrecorded in the table to demonstrate that the advantage according to theinvention is not gained at the expense of disadvantages in these useproperties. The procedure for the determination of the tear strength,elongation at break and brown discoloration is as follows:

a) washing of the crude polymer with deionized water,

b) predrying in a fluidized bed at temperatures up to 130° C.,

c) after-drying for 4 hours at 220° C.,

d) grinding in an air jet mill to a d₅₀ value of about 20 μm,

e) pressing under 350 bar to a cylindrical block weighing 13 kg of ineach case about 208 mm height and diameter,

f) sintering at 380° C. in accordance with a temperature program,

g) peeling off a film 100 μm thick in 200 μm steps and

h) visual evaluation of the color on the remaining block, which ispeeled off to the extent of 90%, in accordance with the following scale:

    ______________________________________                                        Rating             Discoloration                                              ______________________________________                                        0                  none                                                       1                  just detectable                                            2                  clearly visible                                            3                  tea-brown                                                  ______________________________________                                    

Specimens of the 100 μm thick film from the central zone of the blockare used to determine the tear strength and elongation at break inaccordance with DIN 53 455 (strip method).

EXAMPLES

100 l of water and the buffer substance stated in the table areintroduced into a 150 l kettle (pressure container) with a stainlesssteel lining. The contents of the kettle are freed from atmosphericoxygen by purging with nitrogen and evacuating, several times, and arebrought to the stated reaction temperature. The stated amount of PPVE isinitially introduced into the mixture and TFE is forced in up to 10 bar.The reaction is started by rapidly pumping in the aqueous solution ofthe stated initiator.

The PPVE is metered in continuously at the rate stated in the table upto a conversion of about 95% of the TFE employed. The pressure is keptconstant by continuous topping-up with TFE, and the reaction temperatureis also kept constant. After conversion of the desired amount theaddition of TFE is ended, the kettle is depressurized and residualmonomers are substantially removed by alternate evacuation and purgingwith nitrogen twice. The contents of the kettle are cooled to roomtemperature and pumped off over a sieve. The crude polymer is washedtwice with about 100 l of deionized water.

The washed crude polymer is predried in a fluidized bed at temperaturesup to 130° C. After-drying at 220° C. for 4 hours follows. The dry crudepolymer is then ground in an air jet mill to a d₅₀ value of about 20 μm,the content above 33 μm not exceeding 5% by weight. The finely groundproduct is pressed to a cylindrical block, as described above, the blockis sintered and a film is peeled off.

The abbreviations in the table are as follows:

APS: Ammonium persulfate

AmCarb: Ammonium carbonate

KPS: Potassium persulfate

Na₂ Ox: Disodium oxalate

K₂ Ox: Dipotassium oxalate

                                      TABLE                                       __________________________________________________________________________             PPVE  Metering                                                           Temper-                                                                            initially                                                                           rate g of                                                                          Initiator                                                                            Buffer  PPVE   SSG Tear       Evaluation           Exam-                                                                             ature                                                                              introduced                                                                          PPVE/kg                                                                            Amount/                                                                              substance                                                                             Incorporation                                                                        density                                                                           strength                                                                           Elongation                                                                          of brown             ple °C.                                                                         in g  of TFE                                                                             Type   Amount/Type                                                                           % by weight                                                                          g/cm.sup.3                                                                        N/mm.sup.2                                                                         at break                                                                            streaks              __________________________________________________________________________    1   70   35    1.7  5.0 g/APS                                                                            20 g/AmCarb                                                                           0.087  2.171                                                                             37.7 680   1                    2   70   35    1.7  5.0 g/APS                                                                            20 g/AmCarb                                                                           0.090  2.170                                                                             37.5 690   1                    3   70   35    1.7  5.0 g/APS                                                                            10 g/AmCarb                                                                           0.094  2.171                                                                             35.6 675   2                    4   70   70    0.6  5.0 g/APS                                                                            20 g/AmCarb                                                                           0.096  2.170                                                                             36.1 655   2                    5   70   70    0.6  4.0 g/APS                                                                            20 g/AmCarb                                                                           0.098  2.171                                                                             36.8 715   2                    6   70   60    0.7  4.0 g/APS                                                                            20 g/AmCarb                                                                           0.102  2.169                                                                             34.8 695   0                    7   63   35    1.7  8.0 g/APS                                                                            40 g/AmCarb                                                                           0.100  2.169                                                                             34.5 715   3                    8   63   35    1.7  8.0 g/APS                                                                            40 g/AmCarb                                                                           0.095  2.169                                                                             36.7 705   1                    9   63   70    0.6  10.0 g/APS                                                                           50 g/AmCarb                                                                           0.115  2.168                                                                             37.9 680   2                    10  63   70    0.6  10.0 g/APS                                                                           50 g/AmCarb                                                                           0.120  2.170                                                                             33.1 710   2                    11  70   35    1.7  4.5 g/KPS                                                                            3.5 g/Na.sub.2 Ox                                                                     0.092  2.170                                                                             32.8 705   0                    12  70   35    1.7  4.5 g/KPS                                                                            3.5 g/Na.sub.2 Ox                                                                     0.089  2.171                                                                             33.1 710   0                    13  70   35    1.7  4.5 g/KPS                                                                            7.5 g/K.sub.2 Ox                                                                      0.093  2.172                                                                             36.4 715   0                    14  70   70    0.6  5.5 g/KPS                                                                            9.0 g/K.sub.2 Ox                                                                      0.098  2.173                                                                             36.6 690   0                    15  70   70    0.6  5.5 g/KPS                                                                            9.0 g/K.sub.2 Ox                                                                      0.108  2.172                                                                             33.8 715   0                    16  63   60    0.7  9.0 g/KPS                                                                            7.5 g/Na.sub.2 Ox                                                                     0.113  2.171                                                                             35.4 720   0                    17  63   35    1.7  9.0 g/KPS                                                                            7.5 g/Na.sub.2 Ox                                                                     0.093  2.169                                                                             37.3 665   0                    18  63   70    0.6  9.0 g/KPS                                                                            9.0 g/K.sub.2 Ox                                                                      0.120  2.164                                                                             34.5 690   0                    19  63   70    0.6  9.0 g/KPS                                                                            9.0 g/K.sub.2 Ox                                                                      0.107  2.171                                                                             34.8 700   0                    __________________________________________________________________________

We claim:
 1. A process for the preparation of a non-melt-processabletetrafluoroethylene polymer having a content of 0.01 to 1% by weight ofperfluoro-(alkyl vinyl) ether units with 1 to 4 carbon atoms in theperfluoroalkyl chain, which comprises the step of reacting the monomersby suspension process in an aqueous medium containing at least oneinitiator and at least one polymerization auxiliary, said aqueous mediumbeing essentially free of ammonium salts, the amount oftetrafluoroethylene and the amount of perfluoro-(alkyl vinyl) etherunits being selected such that the resulting polymer isnon-melt-processable.
 2. The process as claimed in claim 1, wherein atleast one said initiator is an alkali metal persulfate or an alkalineearth metal persulfate.
 3. The process as claimed in claim 1, whereinthe initiator is a lithium, sodium, or potassium salt or a mixture ofsaid salts.
 4. The process as claimed in claim 1, wherein thepolymerization is carried out at 60° to 80° C.
 5. The process as claimedin claim 1, wherein the tetrafluoroethylene is metered in under apressure of about 5 to about 15 bar.
 6. The process as claimed in claim1, wherein the polymer of tetrafluoroethylene has a content of from 0.02to 0.25% by weight of ether units.